Strenghtening portlight holes

[woodymr]

Ahoy, I would like to have opinions on best method for sealing 5"x16" holes in 1" thick cabin for installation of 5"x9"x3/8" glass aluminum opening portlights. I want a strong repair then cut out new hole for portholes. Thanks for any imput

[hoytedow]

What material are the 1" thick walls made of? How is the material finished? Is it wood, varnished or painted?

[woodymr]

Hey, thanks for reply, '76 Columbia 9.6 #42 Good thick fiberglass woven mat, 1" thick, may have wood core not sure but thick and strong, just want repair to be as strong. Of course the outside is gel-coat and the inside is stripped so one can see the mat design in the fiberglass, doing a major refit of the boat, so cosmetics are least of my concern a the moment. I'm thinking I must get something inset into cabin wall not just fill in hole and patch, you know what I mean? Thanks agian

woodymr, you are going to have to find out the construction or get us pics of the endgrain.

[woodymr]

Thanks for input, endgrain? it's a fiberglass wall 1" thick, that's alright I'll make it. Thanks for help.

It is not a fiberglass wall one inch thick.

[woodymr]

OK, I'll bite: You know where the "old" portlights ( holes cut in cabin covered with Plexiglass ) were? I suffer from ADHT.ing so I'm doing this un-like most who would purchase new portlights sized to fit in existing holes or larger to only enlarge the hole cut-outs, I have (worthy) portlights that are smaller than my cutouts, so I intend on covering the holes in my cabin and then cut out new holes for my (worthy) portlights. Sorry if I am confused, but lack of nicotene produces strange behavioral patterns in me lately, as I am trying to quit enhaling carbons having switched to fiberglass particles, sorry I'm rambling, have looked at sites http://www.triton381.com/ that show fiberglassing to the beveled side of holes, I just think I could strengthen by adding something, maybe I'm getting too hypothetical here........ like adding steel security bars in a house window, I do not want my new repair job on portlights to be stoved in at sea thats all.... thanks for your replies

Hmm,

a boat that size will most probably have plywood encapsulated in GRP when it is one inch thick!

[woodymr]

I think you are right. I am guilty of over engineering at times. Thanks